Transcript Development Roadmap

Fleet Performance and Reliability
in Generation Utilities
Rodney Lord, IT Solutions & Services, Siemens
Jörn Rassow, Power Plant Engineer, EnBW Kraftwerke AG
© 2008 Eventure Events. All rights reserved.
Energy Management Suite
Siemens IT-Solutions and Energy
Protection notice / Copyright © Siemens AG 2008. All rights reserved.
Combining Technical and Business Information
with Siemens Energy Management Suite
Efficiency
QUALITY
Availability
Emissions
Fuel costs
Flexibility
Performance
Maintenance costs
TIME
COSTS
Operating costs
Business Performance Management
Generation Planning
& Monitoring
Technical Performance
Management
Instrumentation
Alarming
Corrective &
Preventive Maintenance
1)
Operations &
Maintenance 1)
Shift Management
1) Available in 2008
Power Plant 1
Power Plant 2
Power Plant n
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October 2008
Siemens IT Solutions and Services
Enterprise Wide Decision Support
Executive
Management
Technical
Competence
Center
User Community
• Executive Management
• Power Plant Management
• Production Management
• Technical Management
Production
Manager
Power Plant
Manager
Systems
• Plant Systems
• IT systems
Process Data Internet
Intranet
Archive
Multiple
Generation
Locations
Power Plant 1
SAP ERP
Databases
DCS
Power Plant 2
Scheduling Energy
Trading
...
Power Plant n
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October 2008
Siemens IT Solutions and Services
Integration of SAP Enterprise Asset Management, SAP
ERP Systems and Plant Process Information provides
visibility to key operational data and information
SAP
SAP
ERP
ERP
Planning
&
Execution
Energy
Management
Suite
Plant
Plant
Control and Operational
Control and Operational
Systems
Systems
Limited visibility
to plant operations
and metrics
Energy Management Suite
is the bridge between
plant operations
and the business
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October 2008
Siemens IT Solutions and Services
Enterprise Wide Decision Support
Executive
Management
Technical
Competency
Center
User Community
• Executive Management
• Power Plant Management
• Production Management
• Technical Management
Systems
Production
Manager
Energy Management Suite
• Plant Systems
• IT systems
Multiple
Generation
Locations
Power Plant
Management
Power Plant 1
Power Plant 2
Power Plant 3
Kraftwerk 2
EMS connects data from the power generation and business areas with process know
how to creating transparency and flexibility.
Access to this near real time information enables decision making to increase
availability and profitability.
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October 2008
Siemens IT Solutions and Services
Fleet Wide Monitoring & Decision Support
- The Building Blocks
SAP Netweaver Enterprise Portal
Provides a Single User Interface
EMS
Operational Data
Collection and Processing
SAP ERP
Plant Management
Maintenance and Workforce
Plant and
IT Systems
Process Data Internet
Intranet
Archive
SAP ERP
Databases
DCS
Scheduling Energy
Trading
...
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October 2008
Siemens IT Solutions and Services
Energy Management Suite
- Primary Functional Areas
EMS Portal
Fleet Generation
Monitoring and Planning
Fleet
Performance Monitoring
Fleet-wide
Diagnostics & Optimization
Business Performance Management
Operational Management
Enterprise Information Center
Alarm
Processing
Technical
Perform. Mgmt.
Generation Planning
and Monitoring
Process Information
(OSI PI – Process Book)
Plant Asset Management (PAM)
SAP Plant Management
EMS PAM Extensions
Core PAM
Corrective &
Preventive
Maintenance
SAP ERP
Shift
Management
Maintenance &
Workforce
PM,
WCM
PS
SAP Netweaver
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October 2008
Siemens IT Solutions and Services
Enterprise Information Center
– Utilizing the SAP Enterprise Portal and eSOA
Enterprise Information Center
•
Integrates information from multiple
power plant locations into a common
platform
•
Provides easy access to information from
other integrated ‘expert’ systems
•
Allows a comprehensive view to
company wide information delivered
through a single user interface
•
Access to near real-time information from
the fleet
•
High degree of integration among plant
and business systems
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Siemens IT Solutions and Services
Siemens Energy Management Suite
- Shift Log for Asset Performance Management
Shift Management
•
•
•
•
Planning of shifts and shift crews
Manual or automatic logging of events
and DCS signals
Replaces paper based Operator Logs
Shift Tasks e.g. operator rounds
Maintenance Strategy
•
Multiple maintenance strategies to select
from
Plant Management
•
Core Plant Management (e.g. Master
Data, Maintenance and Materials
Management) integrated with SAP ERP
Availability:
Maintenance and Plant Data Management
Minimizing the risk of unplanned outages
Maintenance: Spare Parts and Maintenance Management
Reduced lead time for planned outages
Reduction in spare parts inventory
Savings
 900,000 €/y
 115.00 €/y
 1.600.000,-€/y
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October 2008
Siemens IT Solutions and Services
Siemens Energy Management Suite
- Early Warning System for Diagnostic and Technical
Performance Management
Predictive Diagnostic System
•
•
•
•
•
Savings of more than $8 M/Yr.
Improved efficiency for:
- Lignite-fired units:
2%
- Gas-fired units:
1.5%
Fleet-wide plant condition
monitoring and alarming system
Asset status reporting integration of
the local Vibration system with EWS
Creation and tuning of the plant
operational models
Review of selected thermal cycle
calculation system
Integrated Alarming into Shift Log
component
Additional 50 MW capacity
Additional output of nuclear power plants:
+ 2MW
Fleet availability increased by 0.5%
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October 2008
Siemens IT Solutions and Services
Siemens Energy Management Suite
- Expert System for Generation Planning and
Monitoring
Fleet Dash Board
Availability/Capability
•
Event Logging - Visualization of
past capability and projections for
the future
Economic Dispatch
•
Economic dispatch of a fleet taking
into account the current
circumstances. (e.g. head water
pressure, thermal heat rates, costs)
Generation Monitoring
•
5000 MW installed generation capacity
Average fuel reduction of 0.5% [0.3-1.0%]
Average fuel costs of 25 €/MWh
Plant Utilization 60%
-> 3 000 000 €/year
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October 2008
Manage schedules and control
production. Early reaction to
emerging issues
Fuel Supply - and Emissions
Management
•
Monitoring (calculation) of actual
emissions and reporting
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Siemens IT Solutions and Services
Siemens Energy Management Suite
- Business Performance Monitoring
15.10.2008
Key Performance Indicators
•
Calculation and reporting of KPIs on
each unit in the fleet and component
•
MTBF, MTBR
•
IEEE, VGB, …
Technical & Maintenance Reporting
•
Comprehensive business reporting
•
Fleet wide YTD actuals
•
Production forecasts
•
Maintenance order status
and costs
•
….
Business Advisor
Early Detection of Performance Deviations
Benefits for a typical Generation Fleet
•
‘What if‘ planning scenarios for the
fleet based on generation supply
contracts and fuel targets
5000 MW installed generation capacity
Increase of In-Market Availability by 0.5 %; equals 25 MW of
additional generation
Invest of 1.000.000 €/MW installed capacity
Depreciation 10 %/year
-> 2.500.000 €/year
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October 2008
Siemens IT Solutions and Services
Energy Management Suite
- Customer Value
Customer Benefits
Highly innovative solution package
integrating production, business processes
and metrics.
Faster and improved support for decision
making to meet the short and long term
market needs.
Early detection of potential plant and unit
issues lead to;
• reduced maintenance costs
• increased availability and efficiency
• economic and technical optimization of plant
and fleet performance
• consistent management reporting
Customer Experience
Efficienct Technical Performance:
Early Detection of deviations
 500.000 €/y (800MW, coal-fired steam power
plant)
Generation Monitorong.&Planning:
Optimized Generation Schedule Planning
 3.000.000 €/y (5000 MW installed capacity)
Availability Monitoring and Alarming:
Avoidance of unplanned outages, and avoided asset
damage
 720.000 €/y (300 MW Combined Cycle Unit)
Early Detection of Performance Deviations:
Increased Asset Utilization
 2.500.000 €/y (5000 MW installed capacity)
* Actual savings achieved by an existing EWS
Customer
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October 2008
Siemens IT Solutions and Services